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University TENAGA NasionalLecturer: Dr. HABEEB ALANI Energy - Electricity To run the machines - Compressed air To run the pneumatic systems and clean machines and products - Steam To run the turbines and utilized in produce of polystyrene (Expansion OP.) - Gas To use it in Furness, welding operations and boilers. INPUT

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University TENAGA NasionalLecturer: Dr. HABEEB ALANI Mass Production Features: - Goods are produced at a high volume for considerable period of time ( > parts per year). - Machine are not flexible (They are not able to produce other types of products). - Products of this type of mfg are the cheapest. a

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University TENAGA NasionalLecturer: Dr. HABEEB ALANI Moderate production Features: - Variable products (depends on the sale order and the market demand) (2, ,000 parts per year). - Multipurpose machine tools and CNC machine tools are usually used in this type of mfg. - Product Ex.: Tools, Moulds, Radio transmitters. b

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University TENAGA Nasional Lecturer: Dr. HABEEB ALANI Job-lot production Features: - The plant does not any specific type of products but it is able to produce any type of product that the market is in need of. - Products move in lots between mfg processes ( parts per lot). - Machine are more flexible and universal. c - Product Ex: Airplanes, Automobile parts, and Plastic products.

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University TENAGA NasionalLecturer: Dr. HABEEB ALANI C oncurrent Engineering CE -It is a philosophy that promotes interactive design and manufacturing efforts to develop product and processes simultaneously. CE is not an enginee- ring discipline. - CE Objective: Optimizing the use of company resources and reducing time to market cycle.

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University TENAGA Nasional Lecturer: Dr. HABEEB ALANI P roduct and Process Development and Prototype validation -CE Function: Product improvement for assembly and mfg Development the mfg and assembly processes Establish baseline process technology Establish program goals and risk-reduction plans freezing a b c d Ph.-2 This is the phase in which the CE team will

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University TENAGA NasionalLecturer: Dr. HABEEB ALANI Cont…… Generally other project elements are addressed I this phase, such as financial business plans, product concept demonstration, freezing of engineering content, and final project approval. Note: Ph.-2

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University TENAGA NasionalLecturer: Dr. HABEEB ALANI Process Validation and Product Design Confirmation : The Production process and methods are finalized Simulation and pilot runs are conducted to test critical steps Machine and equipment are validated for production readiness, quality and performance a b c Ph.-3 This is the execution phase where

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University TENAGA NasionalLecturer: Dr. HABEEB ALANI Production and continuous improvement : - T his face is the Acceleration of production floor into Full rated capacity. This means: Attaining high product quality at the lowest costs. Ph.-4

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University TENAGA NasionalLecturer: Dr. HABEEB ALANI Design, Material and Production 1-3 -A ccording to the existing machine tools and the designed product we choose the raw materials. On the other hands, according to the existing materials and required quality we choose the machine tools.

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University TENAGA NasionalLecturer: Dr. HABEEB ALANI - I n order to attain a high production rate with a low labor cost, Automatic features have been built gradually in different machine tools. Nowadays we deal with fully automatic machine tools and computer aided design and manufacturing (CAD/CAM). But the problem is that maintenance of such automatic machines is very expensive. - Efficiency of production :

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University TENAGA NasionalLecturer: Dr. HABEEB ALANI - T he quality and accuracy must be maintained for the whole mfg processes so at the output we produce parts that can be quickly assembled (interchangeable). Cont….. Efficiency of production

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University TENAGA NasionalLecturer: Dr. HABEEB ALANI - E conomical production is determined by: A functional simple design that has appropriate quality (no more or less). 1 A material choice that represents the best compromise among physical properties, cost, and machinability. 2 The selection of mfg processes that provide the plant with required quality and accuracy (no more accuracy than necessary) at the lowest possible cost. 3

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University TENAGA NasionalLecturer: Dr. HABEEB ALANI Materials that are normally combinations of "metallic elements". Metals usually are good conductors of heat and electricity. Metals are quite strong but malleable and tend to have a lustrous look when polished Metals

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University TENAGA NasionalLecturer: HABEEB ALANI Ceramic materials developed for gas turbine rotors are used in aircraft and diesel engine parts. Ceramics Ceramics are generally compounds between Metallic and NONmetallic elements and include such compounds as: - Oxides - N itrides - C arbides Typically they are insulating and resistant to high temperatures and harsh environments.

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University TENAGA NasionalLecturer: Dr. HABEEB ALANI Using advanced polymer materials, organic light emitting diode (OLEDs) displays produce bright, high- contrast display panels with a wide viewing angle. OLED panels are emissive, eliminating the need for the backlight required in display technologies such as liquid crystal displays (LCDs). Plastics Plastics (or polymers) are generally compounds based upon carbon and hydrogen (Organic Compounds). They are very large molecular structures. Usually they are low density and are not stable at high temperatures.

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University TENAGA NasionalLecturer: Dr. HABEEB ALANI Composites Composites consist of more than one material type. Fiberglass, a combination of glass and a polymer, is an example. Concrete and plywood are other familiar composites. Many new combinations include ceramic fibers in a metal or polymer matrix.

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University TENAGA NasionalLecturer: Dr. HABEEB ALANI BioMaterials Materials compatible with an organism (e.g. Humans) that can be used to make implants, prostheses, and surgical instruments. Designed not to provoke rejection by our bodies (skin, blood, bone, etc.), they can be natural (collagen, cellulose, etc.) or synthetic (metallic, alloy, ceramic, plastic, and others). Dental crowns and contact-lenses use biomaterials.

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University TENAGA NasionalLecturer: Dr. HABEEB ALANI The goal of design: To create products that perform their function effectively, safely, at acceptable cost What do we need to know about materials to do this? More than just test data. Test Test data Data capture Stat/Math analysis Design data Successful applications $ Economic analysis and business case Selection of material and process Potential applications Characterization Selection and implementation Materials Information for Design